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SECTION 7B3
BORG-WARNER T5 MANUAL
TRANSMISSION
N O T IC E : W h e n f a s t e n e r s a r e r e m o v e d , a l w a y s r e in s t a l l th e m a t th e s a m e lo c a t i o n f r o m w h ic h t h e y w e r e
r e m o v e d . I f a f a s t e n e r n e e d s to b e r e p la c e d , u s e t h e c o r r e c t p a r t n u m b e r f a s t e n e r f o r t h a t a p p lic a t io n . I f
t h e c o r r e c t p a r t n u m b e r f a s t e n e r i s n o t a v a ila b le , a f a s t e n e r o f e q u a l s i z e a n d s t r e n g t h ( o r s t r o n g e r ) m a y
b e u s e d . F a s t e n e r s t h a t a r e n o t r e u s e d , a n d t h o s e r e q u ir in g t h r e a d l o c k i n g c o m p o u n d w il l b e c a l le d o u t.
T h e c o r r e c t t o r q u e v a lu e m u s t b e u s e d w h e n i n s t a l li n g f a s t e n e r s t h a t r e q u i r e it. I f t h e a b o v e c o n d i t i o n s
a r e n o t f o llo w e d , p a r t s o r s y s t e m d a m a g e c o u ld r e s u lt.
CONTENTS
SUBJECT
PAGE
General D escription...................................................................................................................................................... 7B3- 1
Precautions.................................................................................................................................................................. 7B3- 2
Unit D isassem b ly.......................................................................................................................................................... 7B3- 3
Transmission Disassem bly..................................................................................................................................... 7B3- 3
Mainshaft D isassem bly............................................................................................................................................ 7B3- 3
Drive Gear D isassem bly..........................................................................................................................................7B3- 8
Cleaning and Inspection..........................................................................................................................................7B3- 8
Transmission C a s e ............................................................................................................................................... 7B3- 8
Bearing Rollers and S p a c e rs .............................................................................................................................7B3- 9
Front and Rear B earin g s.................................................................................................................................... 7B3- 9
Synchronizer Blocker R ings...............................................................................................................................7B3- 9
Synchronizer Keys and Springs............................................................................................................................7B3-10
Extension Housing Oil Seal and Bushing R ep lacem ent.............................................................................. 7B3-10
Drive Gear Bearing Retainer Oil S eal..................................................................................................................7B3-11
Transmission Cover...................................................................................................................................................7B3-11
Front Countershaft Bearing.................................................................................................................................... 7B3-12
Unit A s s e m b ly ................................................................................................................................................................7B3-14
Drive Gear A ssem b ly............................................................................................................................................... 7B3-14
Mainshaft A ssem bly................................................................................................................................................. 7B3-14
Transmission Assem bly...........................................................................................................................................7B3-14
S p ecificatio n s.................................................................................................................................................................7B3-17
Fastener Tightening Specifications...................................................................................................................... 7B3-17
Lubrication Specifications...................................................................................................................................... 7B3-17
Special T o o ls .................................................................................................................................................................. 7B3-18
GENERAL DESCRIPTION
The 77-mm 5-speed is a constant mesh transmission,
synchronized in all speeds except reverse.
The main components are:
1. Main drive gear.
• An integral shaft is splined to engage with the
clutch-driven plate.
• The gear drives the countershaft.
• A tapered bearing supports the shaft in the
case.
2. Countershaft.
• The countershaft is one unit for constant rota
tion with the drive gear.
• Bearings support the countershaft in the case.
•T hrust washers limit the play of the counter
shaft.
• An extra gear is mounted to the countershaft for
5th speed.
3. Mainshaft.
• The drive gears rotate freely on the mainshaft
and are in constant mesh with the countershaft.
• Key-type synchronizers engage the gears.
• T h e first and second syn c h ro n iz e r hub is
machined in place.
• A tapered bearing supports the mainshaft in the
rear of the case.
Summary of Contents for S Series 1994
Page 1: ......
Page 11: ...VIEW A p n n n j VIEW C F7554 Figure 10 Hydra Matic 4L60 E Transmission I D Location...
Page 24: ...NOTES...
Page 26: ......
Page 69: ...NOTES...
Page 71: ...3 2 STEERING...
Page 73: ......
Page 84: ......
Page 102: ...40...
Page 130: ...NOTES...
Page 146: ...NOTES...
Page 162: ...NOTES...
Page 166: ...Figure 5 Removing the Pinion Flange Figure 6 Pressing the Drive Pinion from the Cage...
Page 178: ...Figure 3 Spreading the Differential Case Figure 4 Removing the Differential...
Page 190: ...NOTES...
Page 202: ...NOTES...
Page 206: ...F5785...
Page 212: ...B Button Moved Out of Bearing Bore F5791...
Page 228: ...NOTES...
Page 232: ......
Page 234: ......
Page 236: ...Adjuster 63 Bolt 64 Lock Figure 10 Turning the Adjuster Plug K3 Models...
Page 237: ...Figure 13 Removing the Pinion Seal 39 Bearing Cup Figure 16 Removing the Inner Bearing Cap...
Page 261: ...F7475...
Page 267: ...B Button Moved Out of Bearing Bore F5791...
Page 294: ...NOTES...
Page 300: ...NOTES...
Page 318: ...NOTES...
Page 322: ...SR207LN2 EDS...
Page 324: ......
Page 326: ...OVERHEAD OILING AND RETURN MAIN OIL GALLERY N30005 6A2 J EDS...
Page 368: ...103 153 127 V1200...
Page 370: ......
Page 372: ......
Page 374: ...F9375 Figure 7 Engine Lubrication Diagram Engines Without Balance Shaft...
Page 376: ...Figure 9 Engine Lubrication Diagram Engines With Balance Shaft...
Page 399: ...V2974...
Page 410: ......
Page 412: ...195 196 201 174 252 163 165 164 244 3706r3924...
Page 452: ......
Page 454: ...163 164 V1202...
Page 456: ...20 21x 302 210 4 0 41 2 5 2 5 1 2 51 4 2 e3 54 3 9 252 252 S 255 255 25 6 256 209 V1196...
Page 458: ...100 1 8 4 185 183 177 v 75 201 3706r1204...
Page 460: ......
Page 510: ......
Page 512: ...V2131...
Page 514: ...110 106 106 103 90 93 89 88 87 86 v 7 7 7 7 j A _ 111 f t 2 a a s 53 49 L 47 46 3706r4751...
Page 516: ...259 260 150 237 S lM 180 167180 J 1 82 183 170 169 1 1 78 1 7 9 213212 2 0 7 205 r i 3706r4752...
Page 566: ...NOTES...
Page 574: ...NOTES...
Page 618: ...SPECIAL TOOLS...
Page 620: ...NOTES...
Page 672: ......
Page 682: ......
Page 686: ......
Page 694: ...RH0213 4L60 E...
Page 695: ...657 659 m i J 8092 H J 34196 4 3 34196 5 657 658 665 J 23907 J 7004 1 J 8092 RH0214 4L60 E...
Page 696: ...J 8092 J 34196 4 33 31 J 8092 RH0215 4L60 E...
Page 697: ...SPECIAL TOOLS...
Page 698: ...SPECIAL TOOLS...
Page 758: ...RH0194 4L80 E...
Page 764: ......
Page 770: ...SPECIAL TOOLS...
Page 771: ...SPECIAL TOOLS CONT...
Page 772: ......
Page 775: ......
Page 776: ......
Page 785: ......
Page 804: ...NOTES...
Page 806: ......
Page 808: ......
Page 822: ...3707r5079...
Page 840: ......
Page 848: ...NOTES...
Page 852: ......
Page 860: ...F5435...
Page 866: ......
Page 878: ...F9167...
Page 882: ...16 FrontOutputShaft 18 DrivtQNr 19 DrivenGm t 20 DriveChain 22 FrontOutputBearing V2836...
Page 890: ...F9168...
Page 908: ......
Page 919: ......